Motor/encoder assembly for tape drives

ABSTRACT

A magnetic/encoder assembly has a compact design and combines the features of motor, encoder and chuck locating feature within a single motor housing. The motor/encoder includes a DC brushless motor with an inner magnetic rotor. The motor windings and the commutation electronics are mounted towards the bottom side of a printed circuit board. The rotor of the motor is extended above the surface of the printed circuit board. The extended rotor provides a precision seat for the magnetic wheel with multiple poles. The top surface of the printed circuit board mounts the sensor for the encoder. The extension of the rotor provides the precision mounting surface of the cartridge driving chuck.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/243,938, filed Oct. 4, 2005, now U.S. Pat. No. 7,145,272, which is adivisional of U.S. application Ser. No. 10/259,738, filed Sep. 30, 2002,now U.S. Pat. No. 7,126,786 which claims the benefit of U.S. ProvisionalPatent Application No. 60/326,610 filed on Oct. 1, 2001, all of whichare incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the field of tape drives, and moreparticularly, to a motor/encoder system for a magnetic tape drive.

BACKGROUND OF THE INVENTION

In tape drive systems that utilize a single tape cartridge reel, oncethe cartridge is loaded and is registered at the appropriate datum, thetooth ring coupling of the cartridge reel becomes engaged with the motorsystem of the tape drive. The lead end of the tape, which is called theleader block or leader pin, is then transferred from the cartridge reelto the take up reel located inside the tape drive. This take up reel isalso attached to a motor system. Once a leader pin has been successfullymoved to the take up reel, the tape is located against the magnetic headof the tape drive and both of the reels of the tape drive are ready tobe rotated by the motor/encoder, to start the read/write process.

The motor/encoder system of a tape drive may have a number of functions,depending on the design of the tape drive. For example, themotor/encoder system can control the tape speed, regulate tape tensionand align the take-up reel at a precise location to properly receive theleader pin.

As the form-factor requirement of single reel cartridge tape drivesdecreases, the size of the components used to create the tape drive alsodiminish. Recent tape drives the use LTO cartridges have a form factorrequirement of 5¼ inch. One of the requirements of this form factor isthat the entire tape drive must fit into a height of 3¼ inch. Therefore,the motor/encoder system must also be designed to fit and properlyfunction in a very limited space.

Motor/encoder systems for precisely controlling the motor speed areknown. In many such systems, the motor and the encoder are separate,individual components. The problem with this type of design is the spacerequired to accommodate two separate parts; the motor and the encoder.In a tape drive system with a form-factor requirement, there is no spaceavailable for two separate motor and encoder components. Furthermore,providing two separate components normally have a higher cost incomparison to provision of a single component having dual functionality.It also adds assembly time and added cost of inventory.

Another concern of certain encoding arrangements arises because of theuse of a magnetic shaft encoder that employs a gear or a toothed wheelfor inducing periodic electrical pulses in an inductive pick-up. Theteeth of the wheel are evenly spaced and every tooth generates a signalas it passes the pick-up. One problem with such an encoder is itsrelatively limited resolution. This is because the size of the tooth islimited in how small the tooth can be made. In other arrangements, amagnetic code wheel is employed. Such arrangements use an inductive coilconcept or a moving coil, movable together with a rotor, that interactswith the magnetic code wheel. A major concern with such an applicationis routing of the wire from the movable coil mounted at the center ofthe rotor. It requires a rotary shaft having a through hole formed alongthe axis of rotation of the motor's shaft to route the coil lead wires.

There is a need for an arrangement in which the motor/encoder system ispackaged in the smallest practical volume, yet provide the functions ofhousing a DC brushless motor with its driver circuitry, a magneticencoder with necessary sensors and provide precision mounting andlocating features for a cartridge driver component.

SUMMARY OF THE INVENTION

These and other needs are met by embodiments of the present inventionwhich provide a tape drive comprising a rotor compartment, and meanshoused within the rotor compartment for coupling a rotor to a tapecartridge, rotating a tape cartridge reel, and encoding a position ofthe rotor. In certain embodiments of the invention, a magnetic codewheel is attached to the rotor that is rotatably mounted within themotor compartment. A magnetic code wheel sensor is stationarilypositioned within the rotor compartment, which senses rotation of themagnetic code wheel. The invention thus improves upon the currentlimited resolution offered by devices which employ a toothed ring gearand inductive pick-up. Since all three functions are housed within asingle rotor (or motor) compartment, a compact design can be provided.

The earlier stated needs are also met by other embodiments of thepresent invention which provide a motor/encoder assembly for a tapedrive, comprising a motor housing and a DC motor mounted in the housing.The DC motor has a rotor, a field magnet attached to the motor, motorlaminations and windings. A code wheel is mounted on the rotor withinthe motor housing. A code wheel sensor is fixedly mounted within themotor housing. A chuck mounting element is provided on the rotor.

The earlier stated needs are also met by another aspect of the presentinvention which provides a tape drive with a motor/encoder assemblycomprising a motor housing, a DC brushless motor with driver circuitslocated entirely within the housing, and an encoder with encoder sensorslocated entirely within the motor housing. The tape cartridge driver ismounted on the DC brushless motor.

The foregoing and other features, aspects and advantages of the presentinvention will become more apparent from the following detaileddescription of the present invention when taken conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tape transport mechanism constructedin accordance with embodiments of the present invention.

FIG. 2 depicts a perspective view of a LTO single reel cartridge usablewith the tape drive of the present invention.

FIG. 3 depicts a bottom view of the tape transport in accordance withembodiments of the present invention.

FIG. 4 shows the tape transport of FIG. 1, but with the cartridge loaderremoved for illustrative purposes.

FIG. 5 shows a schematic depiction of a cross-section of themotor/encoder system using a magnetic encoder, constructed in accordancewith embodiments of the present invention.

FIG. 6 shows an assembled motor/encoder system constructed in accordancewith embodiments of the present invention.

FIG. 7 shows the motor/encoder system of FIG. 6 in an exploded view.

FIG. 8 shows a magnetic code wheel assembly constructed in accordancewith an embodiment of the present invention.

FIG. 9 shows a top perspective view of a motor/encoder assemblyconstructed in accordance with an embodiment of the present invention inwhich an optical encoder is employed instead of a magnetic code wheel.

DETAILED DESCRIPTION OF THE INVENTION

The present invention addresses and solves problems related to providingmotor, encoding and cartridge locating features within a tape drive in aparticularly compact manner. These and other problems are solved, inpart, by the present invention which provides a DC brushless motor withan inner magnetic rotor. The motor windings and the necessarycomputation electronics are mounted toward the bottom side of a printedcircuit board. The rotor of the motor is extended above the surface ofthe printed circuit board. The extended rotor provides a precision seatfor a magnetic code wheel with multiple poles. The top surface of theprinted circuit board provides a mounting surface for the necessarysensors for the encoder. The extension of the rotor provides a precisionmounting surface for a cartridge driving chuck. The present inventionthus provides a motor, encoder and cartridge coupling device all to behoused in a single rotor (motor) compartment.

FIG. 1 is a perspective view of the tape transport of a tape drive 10.The housing for the tape drive 10 is not shown to allow depiction of theinternal components of the tape drive 10. A cartridge loader 12 forloading LTO tape cartridges (not shown) is provided on a base plate 15.Underneath the base plate 15 are motor/encoders. A portion of thecartridge reel motor/encoder 14 is depicted in FIG. 1.

The function of the cartridge loader 12 is to load and register the tapecartridge (not shown) on the main datum, which is the surface where thecartridge is placed. The main datum is located on the base plate 15.

The function of the tape-loading mechanics of the tape transport is totransfer the front end of the tape, termed the leader pin, to the hub ofthe take-up reel 24. The magnetic head 18, positioned by a headpositioner system 20, performs the function of writing and reproducingdata on the magnetic recording tape. The tape path system includes anumber of tape guides (generally indicated by reference numeral 22),that are utilized to guide and control the tape motion. FIG. 2 depictsan exemplary embodiment of a LTO, single reel cartridge 26. A portion ofthe cartridge reel 28 is shown. The leader pin 29 is provided at one endof the tape of the single reel cartridge 26.

In FIG. 3, a bottom view of the device 10 of FIG. 1 is depicted. Thereare two motor/encoder assemblies 14, 32 coupled to the base plate 15.The motor/encoder assembly 14 is provided for the cartridge reel 28,while the motor/encoder assembly 32 is for the take-up reel 24. Thecartridge reel motor/encoder assembly 14 engages to the cartridge reel28 when the cartridge 26 is registered in the tape drive 10. The take-upreel 24 is mounted during assembly onto the take-up reel motor/encoderassembly 32. The same motor/encoder assembly configuration may used forboth of the motor/encoder assemblies 14, 32, in certain embodiments ofthe invention.

In FIG. 4, a top view of the tape drive is provided, but the cartridgeloader 16 has been removed from this view in order to better illustratesome features of the present invention. A chuck 34 that drives thecartridge reel 28 is provided above the base plate 15. The chuck isprecisely positioned and mounted on the cartridge reel motor/encoder 14.Specifically, the chuck 34 is mounted on the extension of a rotor of themotor/encoder 14. The arrangement 36 for receiving the leader pin 29 atthe take-up reel 24 is also shown in FIG. 4.

FIGS. 5, 6 and 7 depict a motor/encoder assembly in accordance withembodiments of the present invention. For ease of description purposes,the motor/encoder assembly will be referred to as reference numeral 14,although it should be clear that the same embodiment of a motor/encoderassembly may be employed for the motor/encoder assembly 32.

The motor/encoder assembly of FIGS. 5-7 has a magnetic encoderarrangement. FIGS. 5 and 6 show the assembly in an assembled state,while FIG. 7 is an exploded view of the motor/encoder assembly 14. Themotor/encoder assembly 14 includes a housing 40 that houses a rotor 42mounted on a shaft 44. The rotor 42 and shaft 44 are mounted on ballbearings 46, so the shaft 44 is a rotary shaft.

The motor components include a field magnet 48 attached to the rotor 42.The field magnet 48 interacts with motor laminations and windings 50. Aprinted circuit board 52 is stationarily positioned within the motorhousing 40. The windings 50 are terminated at the bottom surface of theprinted circuit board 52. As can be seen, all of the motor components,including the field magnet 48 and the motor laminations and windings 50,are located axially below the printed circuit board 52.

Axially above the circuit is located a magnetic code wheel 54, in theembodiment of FIGS. 5-7. Magnetic code wheel 54 includes an axiallymagnetized magnet ring 56 held by a magnet-ring holder 58. The magneticcode wheel 54 is held on the rotor 42 by a spacer 70 and a retainerclamp 72. Hence, the magnetic code wheel 54 rotates precisely with therotation of the rotor 42.

A sensor element 60 is located on the top surface of the printed circuitboard 52 and interacts with the magnetic code wheel 54, specifically theaxially magnetized magnet ring 56. The sensor 60 may be a linear hallsensor in certain embodiments of the invention, or a magneto-resistivesensor in other embodiments of the invention.

The rotor 42 also has attached to it a commutation magnet 66 thatinteracts with a commutation sensor 68 located on the bottom surface ofthe printed circuit board 52. A hall sensor may be employed as thecommutation sensor 68.

The rotor 42 extends above the surface of the printed circuit board 52and the mounting surface for the magnet code wheel 54. The extension ofthe rotor 42 includes a chuck mounting feature 62 and a chuck locatingfeature 64. Each of these features provides for precision mounting ofthe chuck 34 that drives the cartridge reel 28 of the single reelcartridge 26. Alternatively, when the motor/encoder assembly is for thetake-up reel 24, the top surface of the rotor 42 serves as the take-uphub-mounting surface. Hence, the same arrangement that provides for themotor and encoding functions, also provides for the chuck locationfeatures of the present invention.

As depicted in FIG. 8, the magnetic code wheel 54 includes the axiallymagnetized magnet ring 56 and a magnet-ring holder 58. In certainpreferred embodiments of the invention, the magnet-ring holder 58 ismade of steel. The magnet-ring holder 58 provides the return path forthe magnet poles.

The magnet poles 74, 76, 74, for example, are alternating north andsouth poles. When the motor rotates, the interaction of the N-S-N-S . .. poles on the magnet ring 56 with the sensor 60 on top of the printedcircuit board 52, as depicted in FIG. 5, provides a sinusoidal waveformoutput. The sensor 60, which may either be a linear hall sensor or amagneto-resistive sensor as mentioned earlier, provides a signal that isfurther processed to derive the necessary pulses which are utilized toperform the conventional encoder-assisted functions, such as controllinga tape tension aligning the take-up hub to receive the leader-pin, andso on.

The compact nature of the design in accordance with embodiments of thepresent invention, as best illustrated in FIGS. 5 and 6, providesadvantages in a number of different manners. For example, the relativelyshorter span of the shaft 44 that supports the mass of the relevantcomponents, provides an increased structural rigidity of the overallsystem in comparison to conventional designs that typically employ alonger shaft. Furthermore, another advantage is the enhanced performanceof the present invention in comparison to conventional arrangements fromthe standpoint of environmental conditions. The motor/encoder systemuses common components for the motor and for the encoder, such as thehousing 40, the printed circuit board 52, the rotor 42 etc. By usingcommon components for the two different systems, the temperature deltabetween the relevant motor and encoder components will be minimized.This increases the accuracy of the servo control of the motor speed andother functions that are controlled by the encoder components.

The use of a magnetic code wheel arranged as in the present inventionimproves resolution, as a finely pitched resolution of the magneticpoles may be provided. Also, a magnetic code wheel is advantageous overan optical encoder by eliminating the need to have a dust cover orequivalent item that is normally necessary to prevent contamination inan optical encoder. Also, the use of hall sensors or magneto-resistivesensors reduces costs compared to an inductive pick-up. There is a clearcost advantage over conventional optical encoder systems.

Since all the encoder sensing elements are mounted on the stationaryprinted circuit board 52, there is no complexity of wire routing from aninductive coil as provided in conventional solutions.

The present invention also can be used with an optical encoder, althougha dust cover is normally needed. FIG. 9 shows the system of the presentinvention with an optical encoder rather than a magnetic code wheel. Theoptical code wheel 80 has chemically etched features and is attached tothe rotor 42 in the same manner as the magnetic code wheel 54 of theembodiment of FIGS. 5-7. The optical code wheel 80 passes through anoptical sensor/detector module 82 that is mounted on the printed circuitboard 52. The optical sensor/detector module 82 includes a light source84 that is below the code wheel 80, and a sensor portion 86 that isabove the code wheel 80.

The optical encoder of the present invention also provides for a compactarrangement in which the motor, encoding functions and chuck locatingfunctions are provided in a compact package.

Due to the compactness of the present invention, the motor/encoderassembly in accordance with the embodiments of the present invention maybe employed in a tape drive that has a 5¼ inch form factor, or that is3¼ inches high.

Although the present invention has been described and illustrated indetail, it is to be clearly understood that the same is by way ofillustration and example only and is not to be taken by was oflimitation, the scope of the claims being limited only by the terms ofthe appended claims.

1. A motor/encoder assembly for a tape drive comprising: a motor housing; a DC motor mounted in the housing, the DC motor having a rotor, a field magnet attached to the rotor, and laminations and windings; a code wheel mounted on the rotor within the motor housing; a code wheel sensor fixedly mounted within the motor housing; a chuck mounting feature on one end of the rotor which extends outside the motor housing; and a chuck locating feature on the chuck mounting feature.
 2. The assembly of claim 1, further comprising a printed circuit board mounted in the motor housing, the rotor extending axially through the printed circuit board.
 3. A tape drive with a motor/encoder assembly, comprising: a motor housing; a DC brushless motor with driver circuits located entirely within the motor housing; an encoder with encoder sensors located entirely within the motor housing; and a tape cartridge driver mounting on the DC brushless motor.
 4. The tape drive of claim 3, wherein the cape drive has a 5¼ inch form factor.
 5. The assembly of claim 1, wherein the code wheel is a magnetic code wheel comprising a magnet-ring holder attached to the rotor, and a magnetic ring mounted to a surface of the magnetic-ring holder.
 6. The assembly of claim 5, wherein the magnet-ring is axially magnetized and has alternating north and south poles around the circumference of the magnet-ring.
 7. The assembly of claim 1, wherein the code wheel is an optical code wheel, and the code wheel sensor includes a U-shaped module with a light source and a sensor portion, positioned on the printed circuit board such that the optical code wheel passes the light source and the sensor portion.
 8. A tape drive comprising: a motor housing; a DC motor mounted in the housing, the DC motor having a rotor, a field magnet attached to the rotor, and laminations and windings; a code wheel mounted on the rotor within the motor housing; a code wheel sensor fixedly mounted within the motor housing; and means housed within the motor housing for coupling a rotor to a tape cartridge, rotating a tape cartridge wheel, and encoding a position of the rotor, the means including said rotor rotatably mounted within the motor housing; and a printed circuit board stationary mounted in the motor housing, the sensor being mounted in motor housing on a top surface of the printed circuit board, and magnetic code wheel being mounted on the rotor axially above the top surface of the printed circuit board.
 9. The tape drive of claim 8, wherein the laminations and windings are positioned in the motor housing axially below the printed circuit board.
 10. The assembly of claim 8, wherein the code wheel is a magnetic code wheel comprising a magnet-ring holder attached to the rotor, and a magnetic ring mounted to a surface of the magnetic-ring holder.
 11. The assembly of claim 10, wherein the magnet-ring is axially magnetized and has alternating north and south poles around the circumference of the magnet-ring.
 12. The assembly of claim 8, wherein the code wheel is an optical code wheel, and the code wheel sensor includes a U-shaped module with a light source and a sensor portion, positioned on the printed circuit board such that the optical code wheel passes the light source and the sensor portion. 